1968 Mercury 3.9HP Vintage Outboard Carburetor and Fuel Pump Rebuild

[@doi467]

i cannot thank you enough for this video. cheers man!! i wish i could buy you a beer.

[@buckfifty3470]

Really enjoy this series on the ol' '68 you brought back into shape. Just recently purchased a'77 4.5 h.p. Merc that's been collecting dust in a garage for 8-10 years... seller couldn't say for certain. Runs great but will be replacing what's left of the impeller. Fairly certain I found all the pieces. Waiting for my hand held pressure tester to show up (thank you very much) then will order parts as needed. Thanks for sharing your knowledge. Cheers!

[@steve-ip1cd]

Cool! Thanks for the video! My neighbor just gave me a 1964 6hp Merc and the carburetor looks very similar.

[@TimsWorkshopTJY]

I did a 70 mercury outboard 9.8 on some of my videos a year or so and I changed out the carb fuel line with swedge fittings with regular threaded 90 degrees with barbs. Then put on stainless hose clamps and trimmed the long ends off. Also replaced the choke plastic lever post with a metal one and drilled dowel holes to hold everything back together. Even the original knob and bonded to the dowel pin on that end. Like your video. Good job

[@danmcginn772]

after cleaning my carb,making a new fuel line(I put a piece of normal hose between the two brass groumets) ,gasket sealed the fuel pump and cleaned n set the points,installed new impeller-mine runs like a charm,great motor except to work on,lol

[@vvgfg5531]

how did you make that new fuel line?

[@jasonkinney1471]

great videos very informative !

[@bryancook4096]

Excellent video........can you list the source and part numbers of the 3 replacement packages you used? Thanks!

[@johnshuster6946]

I need them as well. Must have been a Mercury day.

[@bryancook4096]

@@johnshuster6946 If you find them, please let me know! Thanks

[@johnshuster6946]

@@bryancook4096 21-22974A3 fuel pump rebuild with check valves, 31503A1 for rebuild kit without check valves. 1395-92621 for the carburetor rebuild kit.

[@bryancook4096]

@@johnshuster6946 which supplier? Thanks so very much. Bryan

[@johnshuster6946]

@@bryancook4096 Marineengine.com or Ebay

[@Usgkdbjodbk]

This video had almost everything I needed, except I really was needing to see how the gaskets get put back on for the fuel pump, I cant seem to get mine to pump fuel through it with the new gaskets

[@dennisfalan1623]

Where can I find your video on reinstalling the Lower Unit after water pump replacement?

[@michaelthomas7898]

many parts are not available gaskets are but not parts and next time take the filter housing off much easier you won't have to pull the choke apart or alter wrenches. nice video mine needs new check valves

[@brentolson8531]

I have a 9.8 hp and the fuel pump is not fixed directly to the carb, I'm having problems with the motor running and starting. I think it's fuel related but not sure there's a vid on my channel if you could help it would be greatly appreciated. Thanks and great vid I'll be rebuilding my carb and pump

[@wideopenangling2123]

Does anyone have a link to those fuel pump diaphragms?

[@danmcginn772]

Mine dumps water out of the exhaust exit under the rear of the cowl,as well as the pee hole,do you think that's normal,because it runs well and doesn't seem hot?

[@buckfifty3470]

My understanding is that's by design.

[@rickydowdenrd]

I see this video is at least 6 years old but could you let me know A ballpark figure on how much it would take to have someone rebuild that engine

[@A_Frog_from_mars12]

I have the exact same motor, this year I tried to start it, but the ignition coil was only outputting about 25V.

[@mj23sn13lt21]

The Orange cover at the beginning I need to take it off to replace the positive and negative wires how do I do that

[@danielgarfias748]

Do you know where I can get a complete carb for that mercury kiekhaefer 3.9 hp engine?

[@bassmith448bassist5]

I have this exact motor. Where can I buy a gasket set for it????? Desperate.

[@vvgfg5531]

Thanks sooooo much for the video mate. Helped me heaps! Only one question though. What size is that brass elbow fitting that connects the line to the fuel pump? Is it 7/16”? I need to customize a new fuel line so it’s a bit longer I live in Australia and have no idea where to find them. Any tips on a good online store?

[@LivetofishOutboardRepair]

I have the exact same motor and I’m having problems rebuilding the fuel pump. It keeps leaking fuel on each side of the center of the pump when priming and running the motor. What do you recommend to stop this pump from leaking fuel?

[@pulverbeschichtungrb5505]

Hi, its a great Video ! I have the same 3.9 mercury. What is the right ingnition time ? Kan you make a Video?

[@danielsvensson356]

Is there a 3 blade prop for these engines? Ive seen engines with 3 blade props mine (black with blue stripes) merc 40 4 hp has 2. What 3 blade prop should I use size and number?Is it possible to upgrade to a 3 blade prop?

[@Wallers2020]

I have a 1967 merc 60 6hp. When I prime the bulb, fuel leaks out of the lower unit. What could be the issue?

[@danmcginn772]

James could you do some videos on the ignitions of these motors,I got one with thunderbolt ignition,and it's more then peculiar.,u CAN DO IT!!

[@qapsukalek]

just bought the same motor thats been sitting in some ones garage probably needs rebuild kit. where can i get and great vid

[@highlandoutboards]

find parts for this model on marineengine.com, boats.net, or crowley marine

[@peytondean9679]

What order do the fuel pump diaphragms go in? Package comes with 3 pieces in the fuel pump diaphragm kit

[@moonkat5155]

I have a 1966 6 hp Mercury , did you ever find out the correct order that the three diaphragm pieces are installed ...mine looked like it had only two when removed.

[@darkstarthe1886]

Do I have the same motor and I just did a impeller on it and I can't figure out for the life of me where the water circulates out of mine has nowhere for the water to go doesn't come out the side or anyting can you let me know I'm afraid to run it cuz I don't want to overheat it..... PLEASE HELP ME!!!!

[@gabrielfalan7538]

I need the fuel line fitting that goes from the fuel line to the fitting on the motor do you know the model number for that fitting? Thanks

[@loganbarker328]

gabriel falan me too. I’m not sure whether to get the 3/8” or the 5/16”

[@rickydowdenrd]

Link for parts

[@danmcginn772]

I got a few questions hoping youll be nice enough to answer.I got the same motor,the hose you broke, got loose around the brass groumets on mine taking the carb off,Will it be alright?You never showed reinstalling the carb i am guessing because its a bitch with the tolerances of this motor,lol.Why is this hose high pressure when it is not needed on other motors?Why cant you just clamp a normal hose on this brass fitting and put a normal fuel line connector on the other end?What kind of silly fuel line connector is this??These motors are a pain in the%%%%% to work on compared to OMC.I am thinking about cutting back the two carb stud mount bolts for easier carb installation,has this ever been tried,because it would make getting this carb on n off a hell of a lot easier??Just looked under the flywheel,HAAAA!,should be fun getting the coil off,you should post a video of that!!Gonna stick to my old Jonsons n Evinrudes after defeating this bitch,lol.

[@highlandoutboards]

You might get lucky. Only way to know for sure is to connect fuel tank to the connector, prime the bulb to pressurize the fuel system and check for leaks. If no leaks, that's a good sign. It may still be possible for air to leak into the fuel system if you don't observe leaks during the pressure test. One symptom of air getting into the fuel system is fuel pump will not be able to draw fuel into the carburetor. This results in the engine stopping after it has run for a little while. If all else fails, Replacement fuel lines are still available in limited quantities. I think I got the one for this outboard at Crowley marine online.

[@danmcginn772]

thanks for responding even though you only answered one of my questions

[@moonkat5155]

What order do the fuel pump diaphragms go in? Package comes with 3 pieces in the fuel pump diaphragm kit

[@bryancook4096]

Martin....did you find out the answer? Cheers

[@bryancook4096]

The fuel pump repair kit comes with two hard gaskets and a diaphragm. In what order do they go into the fuel pump housing facing towards the carb? Thanks